Brodock Press--Hidden Treasure
With a digital workflow came certain necessities, such as the Kodak Approval XP4, IRIS proofers and the Scitex Lotem platesetter. Brodock also added a plate image reader for its Heidelberg presses, which allows for the presetting of all ink keys on-press. Automation was also the goal with the acquisition of an Accel ink monitoring system to maintain consistency in all fountains throughout an entire run.
Two new MBO Perfection folders, a B-26S (26x50˝) and B-32S (32x51˝), complement the bindery, which recently reaped a 3,500-square-foot expansion. Folding speed and short makeready times, of course, were main objectives for Brodock Press, but so was ease of use—especially in an industry with a severe shortage of skilled operators.
"It's much easier to have one or two really good people operate several pieces of machinery, as long as the machinery is productive and easy to set up—of which the MBO is," Hausle observes. "At that point, you man it with operators who are conscientious, teamed with helpers to load and unload. That was a real productivity boost for us."
Don Weagley, vice president of plant operations for Brodock Press, also contends that the MBO folders were critical acquisitions. Buoyed by their spiral roller configurations, both folders can handle the wide range of paper stocks that Brodock employs—including those with aqueous coatings and varnish—with mark-free results. The optional Rapidset system was installed on the B-26S format Perfection but not the larger B-32S, which basically handles 16-page signature work.
"We do a lot of standard impositions and can pick up those impositions from the (Rapidset) memory," he says. "That saves considerable makeready time." The microprocessor sets the buckle plates and displays full setup instructions, including slitter shafts and sidelays. Rapidset is preprogrammed with 65 standard folding impositions and has memory capability for 250 more customized folds.